METHOD OF REPLICATING OPTICAL ELEMENTS AND REPLICATED OPTICAL ELEMENTS
Flow barriers such as trenches ( 144 ) and/or walls ( 152 ) laterally surrounding an aperture ( 142 ) in a coating ( 140 ) on a transparent substrate ( 120 ) help control the flow of replication material ( 124 ) during the formation of a replicated optical element on the aperture ( 142 ).
1 . A method comprising:
providing a transparent substrate having a coating on its surface, wherein the coating includes an aperture therein, the coating further having at least one trench therein, wherein the at least one trench laterally surrounds the aperture; and
using a replication technique to form an optical element on the transparent substrate in the aperture, the optical element being composed of replication material;
wherein the at least one trench serves as a barrier to flow of the replication material.
2 . The method of claim 1 wherein, during the replication technique, some of the replication material flows over the coating and into the at least one trench.
3 . The method of claim 1 wherein there are a plurality of trenches laterally surrounding the aperture.
4 . The method of claims 1 wherein the optical element is a microlens array.
5 . The method of claims 1 wherein the coating is composed of a chrome.
6 . An apparatus comprising:
a transparent substrate having a coating on its surface, wherein the coating includes an aperture therein, the coating further having at least one trench therein, wherein the at least one trench laterally surrounds the aperture; and
a replicated optical element on the transparent substrate disposed within the aperture, wherein the optical element has a yard portion extending laterally in a direction from the aperture toward the at least one trench.
7 . The apparatus of claim 6 further including a light emitting or light sensing device having an optical axis aligned with the optical element.
8 . The apparatus of claim 6 including a plurality of trenches laterally surrounding the aperture.
9 . The apparatus of claim 6 wherein the optical element is a microlens array.
10 . The apparatus of claim 6 wherein the coating is composed of a chrome.
11 .- 15 . (canceled)
16 . An apparatus comprising:
a transparent substrate having a coating on its surface, wherein the coating includes an aperture therein, the coating further having at least one wall thereon, wherein the at least one wall laterally surrounds the aperture; and
a replicated optical element on the transparent substrate disposed within the aperture, wherein the optical element has a yard portion extending laterally in a direction from the aperture toward the at least one wall.
17 . The apparatus of claim 16 further including a light emitting or light sensing device having an optical axis aligned with the optical element.
18 . The apparatus of claim 16 including a plurality of walls laterally surrounding the aperture.
19 . The apparatus of claim 16 wherein the optical element is a microlens array.
20 . The apparatus of claim 16 wherein the coating is composed of a chrome.